It is an urgent project to realize online and overall condition monitoring and timely fault diagnosis for large-scale mobile and complex equipment. Moreover, most of the existing large-scale complex equipment has quit...It is an urgent project to realize online and overall condition monitoring and timely fault diagnosis for large-scale mobile and complex equipment. Moreover, most of the existing large-scale complex equipment has quite insufficient accessibility of examination, although it still has quite a long service life. The decentralized and overall condition monitoring, as a new concept, is proposed from the point of view of the whole system. A set of complex equipment is divided into several parts in terms of concrete equipment. Every part is processed via one detecting unit, and the main detecting unit is connected with other units. The management work and communications with the remote monitoring center have been taken on by it. Consequently, the difficulty of realizing a condition monitoring system and the complexity of processing information is reduced greatly. Furthermore, excellent maintainability of the condition monitoring system is obtained because of the modularization design. Through an application example, the design and realization of the decentralized and overall condition monitoring system is introduced specifically. Some advanced technologies, such as, micro control unit （MCU）, advanced RISC machines （ARM）, and control area network （CAN）, have been adopted in the system. The system＇s applicability for the existing large-scale mobile and complex equipment is tested.展开更多
Efficient tool condition monitoring techniques help to realize intelligent management of tool life and reduce tool usage costs.In this paper,the influence of different wear degrees of ball-end milling cutters on the t...Efficient tool condition monitoring techniques help to realize intelligent management of tool life and reduce tool usage costs.In this paper,the influence of different wear degrees of ball-end milling cutters on the texture shape of machining tool marks is investigated,and a method is proposed for predicting the wear state(including the position and degree of tool wear)of ball-end milling cutters based on entropy measurement of tool mark texture images.Firstly,data samples are prepared through wear experiments,and the change law of the tool mark texture shape with the tool wear state is analyzed.Then,a two-dimensional sample entropy algorithm is developed to quantify the texture morphology.Finally,the processing parameters and tool attitude are integrated into the prediction process to predict the wear value and wear position of the ball end milling cutter.After testing,the correlation between the predicted value and the standard value of the proposed tool condition monitoring method reaches 95.32%,and the accuracy reaches 82.73%,indicating that the proposed method meets the requirement of tool condition monitoring.展开更多
The Mahalanobis distance features proposed by P.C.Mahalanobis, an Indian statistician, can be used in an automatic on-line cutting tool condition monitoring process based on digital image processing. In this paper, a ...The Mahalanobis distance features proposed by P.C.Mahalanobis, an Indian statistician, can be used in an automatic on-line cutting tool condition monitoring process based on digital image processing. In this paper, a new method of obtaining Mahalanobis distance features from a tool image is proposed. The key of calculating Mahalanobis distance is appropriately dividing the object into several component sets. Firstly, a technique is proposed that can automatically divide the component groups for calculating Mahalanobis distance based on the gray level of wearing or breakage regions in a tool image. The wearing region can be divided into high gray level component group and the tool-blade into low one. Then, the relation between Mahalanobis distance features of component groups and tool conditions is investigated. The results indicate that the high brightness region on the flank surface of the turning tool will change with its abrasion change and if the tool is heavily abraded, the area of high brightness will increase apparently. The Mahalanobis distance features of high gray level component group are related with wearing state of tool and low gray level component group correlated with breakage of tool. The experimental results show that the abrasion of the tool’s flank surface affected the Mahalanobis distances of high brightness component of the tool and the pixels of high brightness component set. Compared with the changes of them, we found that the Mahalanobis distance of high brightness component of the tool was more sensitive to the abrasion of cutting tool than the area of high brightness component set of the tool. Here we found that the relative changing rate of the area of high brightness component set was not quite obvious and it was ranging from 2% to 15%, while the relative changing rate of the Mahalanobis distance in table 1 ranges from 13.9% to 47%. It is 3 times higher than the changing rate of the area.展开更多
Vibration monitoring and vibration severity evaluation of armored vehicle transmission are realized by additional sensors. An algorithm of vibration severity in frequency domain is presented. The algorithm has powerfu...Vibration monitoring and vibration severity evaluation of armored vehicle transmission are realized by additional sensors. An algorithm of vibration severity in frequency domain is presented. The algorithm has powerful applicability for signal type and flexible selectivity for frequency range,and avoids the processing of signal conversion used calculus and filtering compared to the algorithm of vibration severity in time domain. An applied example is given in company with attentive proceedings and measures for improving evaluation effect.展开更多
One of the most important features of the modern ma ch ining system in an "unmanned" factory is to change tools that have been subjec ted to wear and damage. An integrated tool condition monitoring system co...One of the most important features of the modern ma ch ining system in an "unmanned" factory is to change tools that have been subjec ted to wear and damage. An integrated tool condition monitoring system composed of multi-sensors, signal processing devices and intelligent decision making pla ns is a necessary requirement for automatic manufacturing processes. An intellig ent tool wear monitoring system will be introduced in this paper. The system is equipped with power consumption, vibration, AE and cutting force sensors, signal transformation and collection apparatus and a microcomputer. Tool condition monitoring is a pattern recognition process in which the characte ristics of the tool to be monitored are compared with those of the standard mode ls. The tool wear classification process is composed of the following parts: fea ture extraction; determination of the fuzzy membership functions of the features ; calculation of the fuzzy similarity; learning and tool wear classification. Fe atures extracted from the time domain and frequency domain for the future patter n recognition are as follows. Power consumption signal: mean value; AE-RMS sign al: mean value, skew and kutorsis; Cutting force, AE and vibration signal: mean value, standard deviation and the mean power in 10 frequency ranges. These signa l features can reflect the tool wear states comprehensively. The fuzzy approachi ng degree and the fuzzy distance between corresponding features of different obj ects are combined to describe the closeness of two fuzzy sets more accurately. A unique fuzzy driven neural network based pattern recognition algorithm has bee n developed from this research. The combination of Artificial Neural Networks (A NNs) and fuzzy logic system integrates the strong learning and classification ab ility of the former and the superb flexibility of the latter to express the dist ribution characteristics of signal features with vague boundaries. This methodol ogy indirectly solves the automatic weight assignment problem of the conventiona l fuzzy pattern recognition system and let it have greater representative power, higher training speed and be more robust. The introduction of the two-dimensio nal weighted approaching degree can make the pattern recognition process more re liable. The fuzzy driven neural network can effectively fuse multi-sensor i nformation and successfully recognize the tool wear states. Armed with the advan ced pattern recognition methodology, the established intelligent tool condition monitoring system has the advantages of being suitable for different machini ng conditions, robust to noise and tolerant to faults. Cooperated with the contr ol system of the machine tool, the optimized machining processed can be achieved .展开更多
基金This project was supported by the Hebei Provincial Nature Science Foundation (E20070011048).
文摘It is an urgent project to realize online and overall condition monitoring and timely fault diagnosis for large-scale mobile and complex equipment. Moreover, most of the existing large-scale complex equipment has quite insufficient accessibility of examination, although it still has quite a long service life. The decentralized and overall condition monitoring, as a new concept, is proposed from the point of view of the whole system. A set of complex equipment is divided into several parts in terms of concrete equipment. Every part is processed via one detecting unit, and the main detecting unit is connected with other units. The management work and communications with the remote monitoring center have been taken on by it. Consequently, the difficulty of realizing a condition monitoring system and the complexity of processing information is reduced greatly. Furthermore, excellent maintainability of the condition monitoring system is obtained because of the modularization design. Through an application example, the design and realization of the decentralized and overall condition monitoring system is introduced specifically. Some advanced technologies, such as, micro control unit （MCU）, advanced RISC machines （ARM）, and control area network （CAN）, have been adopted in the system. The system＇s applicability for the existing large-scale mobile and complex equipment is tested.
基金Project(51975169)supported by the National Natural Science Foundation of ChinaProject(LH2022E085)supported by the Natural Science Foundation of Heilongjiang Province,China。
文摘Efficient tool condition monitoring techniques help to realize intelligent management of tool life and reduce tool usage costs.In this paper,the influence of different wear degrees of ball-end milling cutters on the texture shape of machining tool marks is investigated,and a method is proposed for predicting the wear state(including the position and degree of tool wear)of ball-end milling cutters based on entropy measurement of tool mark texture images.Firstly,data samples are prepared through wear experiments,and the change law of the tool mark texture shape with the tool wear state is analyzed.Then,a two-dimensional sample entropy algorithm is developed to quantify the texture morphology.Finally,the processing parameters and tool attitude are integrated into the prediction process to predict the wear value and wear position of the ball end milling cutter.After testing,the correlation between the predicted value and the standard value of the proposed tool condition monitoring method reaches 95.32%,and the accuracy reaches 82.73%,indicating that the proposed method meets the requirement of tool condition monitoring.
文摘The Mahalanobis distance features proposed by P.C.Mahalanobis, an Indian statistician, can be used in an automatic on-line cutting tool condition monitoring process based on digital image processing. In this paper, a new method of obtaining Mahalanobis distance features from a tool image is proposed. The key of calculating Mahalanobis distance is appropriately dividing the object into several component sets. Firstly, a technique is proposed that can automatically divide the component groups for calculating Mahalanobis distance based on the gray level of wearing or breakage regions in a tool image. The wearing region can be divided into high gray level component group and the tool-blade into low one. Then, the relation between Mahalanobis distance features of component groups and tool conditions is investigated. The results indicate that the high brightness region on the flank surface of the turning tool will change with its abrasion change and if the tool is heavily abraded, the area of high brightness will increase apparently. The Mahalanobis distance features of high gray level component group are related with wearing state of tool and low gray level component group correlated with breakage of tool. The experimental results show that the abrasion of the tool’s flank surface affected the Mahalanobis distances of high brightness component of the tool and the pixels of high brightness component set. Compared with the changes of them, we found that the Mahalanobis distance of high brightness component of the tool was more sensitive to the abrasion of cutting tool than the area of high brightness component set of the tool. Here we found that the relative changing rate of the area of high brightness component set was not quite obvious and it was ranging from 2% to 15%, while the relative changing rate of the Mahalanobis distance in table 1 ranges from 13.9% to 47%. It is 3 times higher than the changing rate of the area.
基金Sponsored by National Defense Science and Technology Key Lab Foundation of China (51457120104JB3505)
文摘Vibration monitoring and vibration severity evaluation of armored vehicle transmission are realized by additional sensors. An algorithm of vibration severity in frequency domain is presented. The algorithm has powerful applicability for signal type and flexible selectivity for frequency range,and avoids the processing of signal conversion used calculus and filtering compared to the algorithm of vibration severity in time domain. An applied example is given in company with attentive proceedings and measures for improving evaluation effect.
文摘One of the most important features of the modern ma ch ining system in an "unmanned" factory is to change tools that have been subjec ted to wear and damage. An integrated tool condition monitoring system composed of multi-sensors, signal processing devices and intelligent decision making pla ns is a necessary requirement for automatic manufacturing processes. An intellig ent tool wear monitoring system will be introduced in this paper. The system is equipped with power consumption, vibration, AE and cutting force sensors, signal transformation and collection apparatus and a microcomputer. Tool condition monitoring is a pattern recognition process in which the characte ristics of the tool to be monitored are compared with those of the standard mode ls. The tool wear classification process is composed of the following parts: fea ture extraction; determination of the fuzzy membership functions of the features ; calculation of the fuzzy similarity; learning and tool wear classification. Fe atures extracted from the time domain and frequency domain for the future patter n recognition are as follows. Power consumption signal: mean value; AE-RMS sign al: mean value, skew and kutorsis; Cutting force, AE and vibration signal: mean value, standard deviation and the mean power in 10 frequency ranges. These signa l features can reflect the tool wear states comprehensively. The fuzzy approachi ng degree and the fuzzy distance between corresponding features of different obj ects are combined to describe the closeness of two fuzzy sets more accurately. A unique fuzzy driven neural network based pattern recognition algorithm has bee n developed from this research. The combination of Artificial Neural Networks (A NNs) and fuzzy logic system integrates the strong learning and classification ab ility of the former and the superb flexibility of the latter to express the dist ribution characteristics of signal features with vague boundaries. This methodol ogy indirectly solves the automatic weight assignment problem of the conventiona l fuzzy pattern recognition system and let it have greater representative power, higher training speed and be more robust. The introduction of the two-dimensio nal weighted approaching degree can make the pattern recognition process more re liable. The fuzzy driven neural network can effectively fuse multi-sensor i nformation and successfully recognize the tool wear states. Armed with the advan ced pattern recognition methodology, the established intelligent tool condition monitoring system has the advantages of being suitable for different machini ng conditions, robust to noise and tolerant to faults. Cooperated with the contr ol system of the machine tool, the optimized machining processed can be achieved .
